A tandem system, consisting of the WKD-SP
and the TM 4 TS EL, is revolutionizing the terry business.
Karl Mayer develops and manufactures
high-performance warp preparation machines for both weaving and warp knitting
and, in order to do this, uses the synergies that exist between the two
sectors. The WKD-SP is the latest result of this know-how and technology
transfer.
This direct warping machine is based on the
WARPDIRECT machine for the weaving sector, and processes staple-fibre yarns. As
said, this new machine delivers all the performance features of its predecessor
but, above all, its advantages can be exploited by using back beams, with their
wider widths, as sectional warp beams (SWBs) in the warp knitting sector.
Efficient
warping with the WARPDIRECT
Die WARPDIRECT is a universal direct
warping machine for processing every type of staple-fibre yarn. It produces
high-quality beams for the slasher dyeing process in denim dyeing, for
combining all the yarns on the warp beams on the assembling machine, and for
processing in a sizing machine with subsequent warp beam production.
The back beams for these various processes
are of the highest quality. The beams are completely cylindrical, thanks to an
intelligent press roller system and optimum yarn laying, and the yarns are
arranged extremely accurately. A computer-controlled length measuring system
delivers a length accuracy of 0.1 %. The yarns are also handled very gently.
Other advantages of the WARPDIRECT include
its low maintenance costs and high productivity. The maximum warping speed is
1,200 m/min. The easy-to-use, graphic touchscreen guarantees optimum machine
usage. All these advantages enable the WKD-SP to now be used for the production
of SWBs for the warp knitting sector as well.
Efficient
production of towels using the WKD-SP and TM 4 TS EL
The starting point for modifying the
WARPDIRECT to create the WKD-SP was the demands made by the TM 4 TS EL during
use. An efficient direct warping machine was needed to match this efficient
machine for producing warp-knitted cotton terry towels.
The modifications that were needed relate
mainly to the software. The program changes enable constant yarn tension levels
and completely uniform SWB circumferences to be produced. SWBs with the same
circumferences and yarn tension levels are needed, since several of them are
processed at the same time on the TM 4 TS EL.
The SWBs of the new direct warping machine
have the same width as back beams. This means that the number can be reduced
when loading the machine. The direct beaming process becomes more efficient.
For example, with a TM 4 TS EL with a gauge of E 24, a working width of
186" and the normal threading arrangement of 1 in, 1 out, eight SWBs per
axle of the beam frame can be reduced to two large-format ones.
KARL MAYER is putting the emphasis on
flexibility by concentrating specifically on the width of the SWBs. For
example, the extra-wide SWBs can also be used on its tried-and-tested direct
warping machine and, for the WKD-SP, this manufacturer enables back beams to be
processed to suit customer requirements. Customers are, therefore, able to use
beams supplied by both local and global suppliers.